Starter (For 2.7 Kw Type) -- Inspection |
| 1. INSPECT STARTER ASSEMBLY |
- CAUTION:
- As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may become hot and cause injury.
- NOTICE:
- The following tests must be done within 3 to 5 seconds to prevent the coil from burning out.
Mount the starter assembly in a vise between aluminum plates.
Perform a pull-in test.
Remove the nut and disconnect the lead wire from terminal C.
Connect the battery to the starter assembly as shown in the illustration. Check that the clutch pinion gear extends.
If the clutch pinion gear does not move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.Text in Illustration *a Terminal C *b Terminal 50 
Extends
Perform a holding test.
Disconnect the negative (-) lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the clutch pinion gear remains out.
If the clutch pinion gear returns inward, replace the magnet starter switch assembly.Text in Illustration Disconnect
Inspect the clutch pinion gear return.
Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.Text in Illustration Disconnect 
Returns Inward
Perform an operation test without load.
Connect the lead wire to terminal C with the nut.
- Torque:
- 24 N*m{245 kgf*cm, 18 ft.*lbf}
Connect the battery and an ammeter (AC/DC 400 A Probe) to the starter assembly as shown in the illustration.
Text in Illustration *a Terminal 50 *b Terminal 30 *c AC/DC 400 A Probe Connect Connect the battery and an ammeter to the starter assembly as shown in the illustration.
Check that the starter rotates smoothly and steadily while the clutch pinion gear is extended. Then measure the current.
- Standard current:
- 180 A or less at 11.0 V
| 2. INSPECT MAGNET STARTER SWITCH ASSEMBLY |
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
Tester Connection Condition Specified Condition Terminal 50 - Terminal C Always Below 1 Ω Terminal 50 - Switch Body Below 2 Ω
If the result is not as specified, replace the magnet starter switch assembly.Text in Illustration *a Terminal C *b Terminal 50 *c Switch Body
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| 3. INSPECT STARTER BRUSH HOLDER ASSEMBLY |
Inspect the load of the brush spring.
Take a pull scale reading immediately after the brush spring separates from the brush.
- Standard spring load:
- 26 to 45 N (3 to 5 kgf, 5.8 to 10.1 lbf)
- Minimum spring load:
- 12 N (1 kgf, 2.7 lbf)
Check the resistance.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
Tester Connection Condition Specified Condition Positive (+) Brush Holder - Negative (-) Brush Holder Always 10 kΩ or higher
Check the brush length.
Using a vernier caliper, measure the brush length.
- Standard length:
- 20.5 mm (0.814 in.)
- Minimum length:
- 11.0 mm (0.433 in.)
If the length is less than the minimum, replace the starter brush holder assembly.Text in Illustration *a Length
| 4. INSPECT STARTER YOKE ASSEMBLY |
Check the resistance.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
Tester Connection Condition Specified Condition Lead Wire - Brush Always Below 1 Ω Starter Yoke Body - Brush 10 kΩ or higher
If the result is not as specified, replace the starter yoke assembly.Text in Illustration *a Lead Wire *b Brush *c Starter Yoke Body
Check the brush length.
Using a vernier caliper, measure the brush length.
- Standard length:
- 20.5 mm (0.814 in.)
- Minimum length:
- 11.0 mm (0.433 in.)
If the length is less than the minimum, replace the starter starter yoke assembly.Text in Illustration *a Length
| 5. INSPECT STARTER ARMATURE ASSEMBLY |
Check the commutator for dirt and/or burns on the surface.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.
Check the resistance.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
Tester Connection Condition Specified Condition Segment - Segment Always Below 1 Ω Segment - Coil Core 10 kΩ or higher
If the result is not as specified, replace the starter armature assembly.Text in Illustration *a Segment *b Coil Core
Check the commutator circle runout.
Place the armature on V-blocks.
Using a dial indicator, measure the circle runout.
- Maximum circle runout:
- 0.05 mm (0.00197 in.)
Check the commutator.
If the diameter is less than the minimum, replace the starter armature assembly.Using a vernier caliper, measure the commutator diameter.
- Standard diameter:
- 36.0 mm (1.42 in.)
- Minimum diameter:
- 35.0 mm (1.38 in.)
Using a dial indicator, measure the undercut depth of the commutator.
- Standard undercut depth:
- 0.7 mm (0.0276 in.)
- Minimum undercut depth:
- 0.2 mm (0.00787 in.)
Inspect the armature bearings.
Check that the armature bearings rotate smoothly.
If the result is not as specified, replace the starter armature assembly.
| 6. INSPECT STARTER CLUTCH SUB-ASSEMBLY |
Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks.
If the result is not as specified, replace the starter clutch sub-assembly.Text in Illustration Free Lock
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Turn the pinion gear by hand while applying inward force and check the movement of the bearing.
If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.